Building construction



March 2, 1943. l.. A. FALCO 2,312,397

- 4 BUILDING CONSTRUCTION Filed Jan. 27, 1941 s sheets-sheet 1 46 l L lad? 4 March 2,1943. L. A. FALCO 2,312,397

BUILDING CONSTRUCTION Filed Jan. 27, 1941 3 Sheets-Sheet 2 March 2, 1943. L.. A. FALCO 2,312,397

I BUILDING CONSTRUCTION I Filed Jan. 27, 1941 s sheet's-sheet s Patented Mar. 2, 1943 UNITED STATES',

E? QFFICE BUILDING CONSTRUCTION Application January 27, 1941, Serial No. 376,025

' (Cl. 'l2-23) Claims.

This invention relates to improvements in building construction and has particular reference to the application of a relatively thin facing or veneer of artificial stone or the like to a wooden building so that the building will have many advantagesrof a stone building, and will appear and be maintained as such, without the need of painting.

One of the objects of my invention is to provide an inexpensive and practical type of construction having many advantages of stone construction.

Another object is to provide an improved means for securing relatively thin slabs of cementitious material or the like to a wooden backing, this means being of such character that as the wooden portion of the structure shrinks and expands there will be no disturbing action upon the mortar filling around the edges of the slab.

Another purpose is to provide a new form of slab-like unit having securing means for attachment to the rear support, which securing means also serves as an effective ashing for the slab.

To these and other ends the invention consists in the novel features to be hereinafter described and claimed.

In the accompanying drawings:

Fig. 1 is an elevation of a portion of a building wall embodying my improvements;

Fig. 2 is an elevation showing portions of two courses of slabs as positioned against the backing, the mortar filling being omitted;

Figs. 3, 4, 5, 6 and 'l are enlarged sections taken respectively on the lines 3-3, 5 4, 5 5, 6 6 and 'l-I of Fig. 1;

Fig. 8 is a rear View of one of the improved units;

Figs. 9 and 10 are respectively fragmentary edge and face views of por-tions of the unit shown in Fig. 8;

Fig. 11 is a perspective view of a form of unit which I may employ at the corners of the building, and

Fig. 12 is an enlarged and somewhat exaggerated edge view of the upper tab portion of a unit.

In the drawings I have shown for illustrative purposes a facing or veneer construction for wooden buildings in which relatively small slabs of artificial stone are applied in courses to the wooden sheathing of a frame building such as a house, this sheathing being laid in a customary manner against the usual studs or uprights. Building paper may be or may not be used between the sheathing and the finished layer. In

this particular instance the slabs may have a length of say 121 inches, a width of say 61/2 inches, and a thickness or depth of 5/8 inch, although these dimensions are given merely by way of example. Each slab is preferably provided at the upper edge and at both ends with a flexible attaching tab which also acts as a iiashing, as hereinafter pointed out, and which is adapted to underlie or partially underlie the Vmortar filling, this mortar filling being applied in the usual locations.

In Fig. 1 I have shown several courses of slabs having the usual staggered relation. The corner of the building is supposed to be at the left, and at the right is a frame 2l)y for a window. Individual full-length slabs are indicated at 2 l, and at the left of the window appears a shorter slab or dummy 22 provided by breaking off one of the regular slabs, as hereinafter explained.

. In Fig. '2 I have shown parts of two courses of the slabs 2|. In this view the filling mortar is omitted, but in Figs. 3 to '1, inclusive, the Amortar is shownV and indicated by reference numerals 23, 49. In these last-named views the wooden sheathing, which in this particular case is of tongue-and-groove construction, is shown at 24, and it will benoted that this sheathing is supported in the usual manner by studs or uprights 25.

Each slab or unit is preferably of the form illustrated in the drawings, having a cementitious rectangular body 2ia formed to provide at the rear an air space 26 between the slab andfthe backing, this air space being defined by boundary portions extending along the ends of the slab and across the top, as hereinafter more particularly described. Each unit also is provided at the top with a flexible attaching tab or strip 21, and at the ends with narrower attaching tabs or strips 28. These tabs are light and flexible so as to permit considerable shrinkage or expansion of the Wooden backing to which they are fastened v/ithout in any way disturbing the mortar at the edges of the slabs. Moreover, these tabs or strips are of waterproof character so that they serve also for fiashing purposes, as hereinafter more particularly described.

The tabs may be conveniently formed of heavy paper treated so as to be waterproof'without detracting substantially from its fiexibility. In the preferred `form, as illustrated, I form each tab or strip of vtwo layers of heavy kraft or sisal paper, with asphalt interposed between the layers, and on the outer face of the paper is depositedran extremely thin coating of metal such as copper.

This copper coating is so thin that it does not appreciably affect the flexibility of the tab, and nails can be readily driven through the tab, and yet the tab is waterproof and moistureproof and has a very durable nature.

In Fig. 12 one of the upper tabs 21 is shown, and in this View the paper body of the tab is indicated at 29 and the thin copper coating at 38.

Tab 21 is secured to the slab body in an appropriate manner, as by embedding a portion of the tab in the concrete of which the slab is made.

In this particular instance a portion 3| of tab Y 21 extends upwardly from the slab body in a lo- Y cation adjacent the rear face of the slab body, and a portion of the tab whichserves as an anchoring portion is bent to provide the part 32 and the flange 33 which lie in the slab body in the relation shown in Fig. 9, for example. For increasing the anchoring effect, the anchoring pore tion ofV the tab may be provided with holes 34 adapted to be penetrated by the concrete. The tab portion`3| has the coppercoating applied to its forward or outer face, and it will be noted from Fig. 5, for example, that this tab portion is of greater widththan the mortar body tucked in at the upper edge of the slab so as to extend substantially above this mortar body. This tab is fastened to the backing or sheathing, preferably Vby means of nails, one at each ofthe upper corners of the unit, as shown at 35. Y

It will be noted that the end tabsr28 are substantially narrower than the tab 21, and from Fig. 3, it will be seen that in this particular form their Width is `about equal to the widthV of the mortar filling at the end of the slab. It will also be observed that as each slab is provided at both ends with tabs 28, the tabs of two adjacent slabs can be overlapped, as shown in Fig. 3, to provide the bottom of a pocket for the mortar lling. VAt thelower corners of each slab, these ends tabs are fastened in place bynails 36, and a single one of these nails 36 secures two tabs in place, as shown in Fig. 3. The tabs or strips are substantially coextensive in length with the slab margins with'which they are associated.

The uend tabs 28 have anchoring portions 31 and anchor holes 38 similar to those of tab `21. At their upper ends the tabs 28 extend partially over the extended end portions of tab 21, in the relation shown in Fig. 10,7the upper extremity 28a of tab 28 `being located about at the middle of the tab 21. The end 21a of the upper tab is preferablyY arranged to be in line with the free lateral boundary of tab 28, as shown in'Fig.'10.

The air space 26 at the rear of each unit is open to the bottom of the slab, butat the top ofthe slab there is an air-space-dening Wall 39 and at the respective ends of the slab there are air-space-dening Walls 40. Expressed in another manner it may be said that the air space at the rear of the slab is formed by cutting the latter away at the rear so as to leave it of full depth or thickness only along the top margin and along the end margins. The back of this cut-away portion or recess in the slab is preferably provided by a formation of transverse alternating ridges 4| and valleys 42 cast in the slab. 'Ihe valleys 42 extend almost completely across the slab and provide weakened lines along which the slab can bemconveniently broken when it is desired toshortenthe slab for acting as a dummy. For convenience in measuring, these valleys 42 may be arranged at one-half inch intervals, although other intervals can be chosen if desired.

`These weakened lines extending transversely practically across the -slab at regular intervals enable the slab to be shortened to the required degree in a very easy and convenient manner in case the slab is too long for the available space. In order to shorten the slab it may be placed in a vise, with only that part which is to be broken off from the end of the slab protruding, and then one or more relatively light hammer blows will cause the slab to be severed transversely along a straight line in a neat and workmanlike manner. Or, the slab may be shortened when horizonspect to a bench or table. The slab when so -shortened can be used in locations such as shown at 22 in Fig. 1 and in Fig. 7. In such locations an appropriate kind of iiller or flashing may be used, and in Fig. 7 merely by way of example I have shown a separate flashing 43, which may be assumed to be fastened in the angle between the window frame 20 and the wooden sheathing. This flashing 43 may be made of the same material of which the tabs of the slab are made, as previously described.

In Fig. l1 I have shown a slab 44 of angular formation adapted to be used at the corners of buildings. Except for the angular formation this slab is theV same as that previously described, having end tabs and an upper tab which are like Vthose previously described, except that the upper tab, illustrated at 45, is of angular formation. It may be assumed that corner slabs of this kind are employed in certain courses at the corner of the building shown at the left of Fig. l, but I do not always use special slabs at the corners, as the ordinary slabs may be jointed together at the corner, or other expedients may be used, for example, abutting the ordinary slabs against an upright wooden member at the corner of the building.

In building the wall the wooden sheathing 24 is erected in the usual or any preferred manner, and the slabs 2| are then applied to it, usually in courses in which the units are staggered, as in the example shown. VPreferably the upper tab is secured to the sheathing, as the course is laid, by two nails, oneadjacent each corner. The end tabs 0f adjacent slabs are overlapped and fastened to the sheathing by a nailadjacent the bottom of the course in the manner previously described. This leaves the proper space to receive the vertical run of mortar 23 betweenthe adjacent ends of the slabs. This space is shown at 46 in Fig. 2. When the next higher course is applied, the lower edge of each of its slabs is lapped over to a degree on the upper tabs of the lower slabs, as indicated in Fig. 2 at 41, the lower edge of the upper slab being spaced from the upper edge of the lower slab body to such a degree as to provide the mortar-receiving space ,48, shown in Fig. 2. f

The next step is to ll up the mortar grooves or recesses with mortar, the vertical grooves 46 receiving mortar llings 23 and yhorizontal grooves 48 receiving mortar llings 49.

inasmuch as the body of the slab at its lower edge is open at the rear, themortar in the horizontal runs 49 is permitted to pass up behind the slabbody to form locking portions such as shown at 50 in Fig. 4. These locking portions 50 are less depth at these points. F5-

` of appreciable vdepth and have considerable lockamasar tween the slabs, it is naturally forced into 'these spaces in somev degree, and has a natural-tendency to move into and lodge in the space-behind the slab at its lower edge portion. Thus there is a very desirable locking effect upon the mortar which anchors it effectively and prevents -dislodgment, and this anchoring effect is increased and improved by the valley and ridge formation of the slab body at its rear face, -as'previously described, although this valley land ridge formation is not essential in all cases.

One of the important features of my invention is the flexibility of the attaching tabs or strips. Owing to this flexibility the tab is permitted to shift, bend or fold as the underlying wood eX- pands and contracts, and this permitted movement or displacement of the tab in one or -more different localities of its area obviates'o'r reduces the exertion of pressure upon the mortar lling. In other words, as there is a certain amount of flexibility in the tab by means of which the slab is attached to the sheathing, displacement of the sheathing is not transmitted directly to the slab, nor is it transmitted directly to the mortar filling or grouting, on account of the fact that a light exible member, in other words, the tab or strip, is interposed, which is so constituted as to take up or compensate for expanding or contracting movements of the underlying layer. The water-repellent material of which the strip is composed is of such character as not to disturb the mortar joint upon expansion. In this manner the integrity of the artificial stone veneer is preserved, notwithstanding the varying conditions to which the underlying wooden layer is subjected, and the slabs and the mortar filling in a very permanent manner maintain their initial setting.

Another feature of great advantage arises from the fact that the tab or tabs not only serve for purposes of convenient securement, but also as a flashing member or members whereby the slab-like portion is flashed, and made self-flashing by virtue of the fact that one unit overlaps another. For example, as shown at the upper part of Fig. 5, the slab of an upper course has its body portion extended down partially over the upper tab of aslab of a lower course. Also it will be observed that at each lend a unit has-a tab in lateral overlapping relation to the endl tab of an adjacent slab. l

It will be understood that in the preferred form the unit is provided with flashing means extending along both ends and extending along the upper edge, and this is of importance in some aspects of the invention, lbut in other aspects it is unimportant, for broadly the provisions for securing and flashing the slab are believed to be novel whether used in connection with more than one or only one edge of the slab.

The construction described is very simple and easy to manufacture and erect, and yet a wall such as herein described, while relatively thin, provides many advantages of a stone building construction, as the building has the appearance of a stone building and requires no painting or the like for maintenance. Furthermore, with the passing of time the cementitious block will mellow in a manner similar to the mellowing of stone so as to impart a more attractive appearance.

The slab bodies of cementitious material can be provided cheaply, as molding in the form shown or in a similar form is inexpensive. The tabs can be very readily provided at small expense, and can'be readily'cast inthe slabbodies.

For -attachinent'to the sheathing, only'ordinary nails 'arie required. AThus the inexpensiveness 'of the construction will be manifest. By the construction described, the mortar is securely locked in place, but the mortar is not necessary for structural purposes'and even if the mortar should drop out in places-it would not materially weaken 'the wall.

' Where one of the slabs which is of full length is disposed with one end adjacent a membensuch 'as the window frame member 20 (Fig. 6), the e'nd tab maybe folded back to the rear of the slab, as shown at '23b in Fig. 6. This, however, isonly by way of example.

While I have shown and described a preferred form of my invention, it will be understood that the invention is susceptible of many other embodiments, and that various modications and ydetail changes may be made without departing from the principles of my invention or the scope of the claims. For example, I prefer to form the bodies of the tabs of paper, but in the broader aspects of the inventio-n I do not limit myself to the use of this particular material.

What I claim is:

1. A building unit comprising a frangible slab formed at the rear on three sides with flanges to provide an airspace and having extending across the back or bottom of the air space a plurality of transverse weakened lines.

2. A building unit comprising a frangible slab formed at the rear on three sides with flanges to provide an air space and having extending across the back or bottom of the air space a plurality of transverse weakened lines, the weakened lines being at the bottoms of valleys cast in the slab body.

3. A building unit comprising a frangible slab having its body recessed to provide an air space at the rear open to the lower margin of the lslabI but closed olf rfrom the other margins, the back or bottom of the air vspace being provided with alternating valleys and ridges arranged transversely of the slab.

4. A building unit comprising a slab having its body recessed to provide a rear air space open to the lower margin of the slab but closed off from the upper margin and the end margins, said slab being provided along the upper margin and the end margins with projecting flexible flashing members, the body of the slab being formed of cementitious material, and said exible projecting members entering the slab body and being anchored therein along the corresponding margins. 1

5. In a building wall, the combination with a wooden backing, of upper and lower adjacent courses of slabs applied to said backing, each of said slabs having a rear air space open to the lower margin but cut oif from the other margins, the slabs of the lower course carrying upwardly projecting flashing strips fastened to the backing, the bodies of the slabs of the upper course being disposed at their lower parts in overlapping relation to said strips but having their bodies spaced from those of the slabs of the lower course to provide a horizontal mortar-receiving groove, and a filling of mortar in said groove, said mortar filling being extended into the air spaces of the slabs of the upper course.

6. A building unit for wall construction adapted for cutting and iitting, comprising a slab of cementitious material having its body recessed to `provide a rear air space open to the lower margin of the slab but closed off from the upper margin and the end margins, said yslab having on its rear face transversely arranged alternating ridges and valleys, the valleys presenting weakened lines across which the slab can be broken, a light flexible strip of waterproof ma terial attached to the slab at the back thereof adjacent the upper margin and extending upwardly to serve as a ashing and securing means, and similar strips similarly arranged at the ends of the slab.

7. A building unit for wall construction comprising a cementitious slab adapted for cutting and fitting, said slab provided with a recessed back providing an air space, and exible strips disposed in projecting position along different margins of the slab and attached to the slab at' the rear adjacent said margins, said strips serving as flashing and also as securing members adapted for nailing to an underlying wooden support.

8. A building -unit for wall construction, comprising a rectangular frangible cementitious slab adapted for cutting and fitting, said slab having attached thereto adjacent one of its lengthwise margins a light flexible waterproof strip adapted to serve as flashing and for securement of the slab by nails driven through the strip into a wooden backing, said strip adapted to be overlain to an extent by a slab of another course and to provide a flexible shrinkage-compensating backing for a mortar grouting between the courses, and similar strips attached to and carried .by the slab at the respective ends, the slab body being provided at the rear with a recess providing an air' space, and the rear face of the slab boy being formed within the air space recess with transverse weakened lines.

9. A building wall comprising a course of slabs each of which has laterally projecting end ashing strips in overlapping relation to those of slabs adjacent the same, said strips being of flexible water-repellent material and providing with the bodies of the slabs mortar-receiving pockets between adjacent slabs the backs of which pockets are formed by overlapping strips, and mortar in said pockets, said water-repellent material Ibeing of such character as not to disturb the mortar joint upon expansion. l

10. In a building wall, a course of slabs arranged end to end `and fastened to a wooden backing, said slabs having flexible upwardly projecting attaching and flashing strips by which they are secured to said backing attached to and carried by the upper parts of the slabs, and another course of slabs disposed above the first course and having their bodies extending down partially over said strips but spaced from the bodies ofthe slabs in the iirst course to provide a horizontal mortar-receiving groove the back of which is formed by said strips, and a grouting of mortar in said groove, said strips being of water-repellent material of a character to vconserve and maintain the mortar joint upon expansion.

11. A building wall comprising a course of slabs each of which has flexible end strips in overlapping relation to those of adjacent slabs in the same course, said strips forming flexible bottoms of mortar-receiving grooves, mortar groutings in said grooves between the ends of adjacent slabs, said slabs having upwardly projecting flexible strips by means of which they are secured to a backing, and an upper course of slabs having their bodies extending down partially over said last-named strips but spaced from the bodies of the slabs in the rst course to provide a mortar-receiving groove the back of which is formed by said strips, and a grouting of mortar in said groove, all of said strips being of water-repellent `material of a character to conserve and maintain the mortar joints upon expansion.

12. In a .building wall, the combination of a wooden or like backing, a lplurality ofslabs in courses laid against said backing with their bodies spaced apart to provide mortar grooves around the slabs, mortar llings in said grooves, and marginal flashing strips lying lbehind the mortar llings and between them and the backing and constituting the rear walls of the mortar grooves,

each strip being secured to a slab and to the backing and being of a light yielding lexible character so as to provide for retention of the mortar fillings under expansion and contraction of the backing.

13. A building unit comprising a frangible slab having a light exible flashing strip disposed and secured along one of its margins so as to leave the back unencumbered and the slab readily severable, said strip being of water-repellent material of a character to conserve and maintain an overlying mortar joint upon expansion.

14. A building unit comprising a fr-angible molded slab having an attached light flexible flashing strip of a character to conserve an overlying lmortar joint upon expansion, said strip having one edge portion projecting and another edge portion anchored within the slab adjacent and along a margin of the slab.

15. A building -unit comprising a frangible slab formed at the rear on three margins with flanges to provide an air space and having light flexible flashing strips anchored in said flanges along the corresponding margins so as to leave the back of the slab unencumbered.

LOUIS A. FALCO. 

